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Abstract:

A compressor may include a first scroll member having a first spiral
wrap, a first chamber, and a first aperture. A second scroll member may
include a second spiral wrap engaged with the first spiral wrap to form a
series of compression pockets and a second aperture. The first aperture
may be in communication with a first of the compression pockets to
provide communication between the first compression pocket and the first
chamber. The second aperture may be in communication with a second of the
compression pockets. A capacity modulation assembly may include a first
piston preventing communication between the first aperture and a first
passage when in a first position and providing communication when in a
second position. A second piston may prevent communication between the
second aperture and a third passage when in the first position, and
provide communication when in a second position.

Claims:

1. A compressor comprising: a housing including a discharge pressure
region and a suction pressure region; a first scroll member supported
within said housing and having a first end plate, a first spiral wrap
extending from a first side of said first end plate, a first chamber
located on a second side of said first end plate having first and second
passages in communication therewith, and a first aperture extending
through said first end plate and in communication with said first
chamber, a second scroll member supported within said housing and
including a second end plate having a second spiral wrap extending
therefrom and meshingly engaged with said first spiral wrap to form a
series of compression pockets and a second aperture extending
therethrough, said first aperture being in communication with a first of
said compression pockets to provide communication between said first
compression pocket and said first chamber and said second aperture being
in communication with a second of said compression pockets; and a
capacity modulation assembly including: a first piston located within
said first chamber and displaceable between first and second positions,
said first piston preventing communication between said first aperture
and said first passage when in the first position, and said first piston
providing communication between said first aperture and said first
passage when in the second position; a structure supporting said second
scroll member for orbital displacement relative to said first scroll
member and including a recess generally aligned with said second aperture
and third and fourth passages in communication with said recess; and a
second piston located within said recess and axially displaceable between
first and second positions, said second piston preventing communication
between said second aperture and said third passage when in the first
position, and said second piston providing communication between said
second aperture and said third passage when in the second position.

2. The compressor of claim 1, further comprising a floating seal assembly
engaged with said housing and said first scroll member to isolate said
discharge pressure region from said suction pressure region.

3. The compressor of claim 2, wherein said first piston is located
axially between said floating seal assembly and said first end plate.

4. The compressor of claim 2, wherein said first piston is axially
displaceable relative to said floating seal assembly.

5. The compressor of claim 1, further comprising a biasing member that
biases said first piston toward the second position.

6. The compressor of claim 1, wherein said first passage extends radially
through said first scroll member and into said first chamber, said second
passage extends radially through said first scroll member and into said
first chamber, said third passage extends radially through said
supporting structure and into said recess, and said fourth passage
extends radially through said supporting structure and into said recess.

7. The compressor of claim 1, wherein said first piston abuts said first
end plate when in the first position.

8. The compressor of claim 1, further comprising a solenoid having a
communication passage selectively providing communication between said
second passage and said recess, wherein when said solenoid provides
communication between said second passage and said recess, said first
piston is in said first position, and when said solenoid prevents
communication between said second passage and said recess, said first
piston is in said second position.

9. The compressor of claim 1, further comprising a valve assembly in
communication with said second passage and selectively providing a
pressurized fluid to said second passage to bias said first piston toward
said first end plate.

10. The compressor of claim 1, wherein said first chamber is an annular
chamber, said recess is an annular recess, said first piston is an
annular piston, and said second piston is an annular piston.

11. The compressor of claim 1, wherein said first passage is in
communication with said suction pressure region, said first aperture
being exposed to said suction pressure region when said first piston is
in said second position to operate the compressor at a first capacity
less than full capacity.

12. The compressor of claim 11, wherein said third passage is in
communication with said suction pressure region, said second aperture
being exposed to said suction pressure region when said second piston is
in said second position to operate the compressor at a second capacity
less than said first capacity.

13. The compressor of claim 12, wherein said first aperture is disposed
radially outward of said second aperture.

14. The compressor of claim 1, further comprising a valve mechanism in
communication with said fourth passage that selectively provides a
pressurized fluid to said fourth passage to bias said second piston
toward said second end plate.

15. The compressor of claim 1, wherein said second piston abuts said
second end plate when in said first position.

16. The compressor of claim 1, further comprising a valve operable in a
pulse width modulation capacity mode to operate the compressor at an
intermediate capacity between full capacity and zero capacity.

17. A compressor comprising: a shell assembly having a suction pressure
region and a discharge pressure region; a first scroll member supported
within said shell assembly and having a first end plate, a first spiral
wrap extending from a first side of said first end plate, a first chamber
located on a second side of said first end plate having first and second
passages in communication therewith, and a first aperture extending
through said first end plate and in communication with said first
chamber, a second scroll member supported within said shell assembly and
having a second end plate, a second spiral wrap extending from said
second end plate and meshingly engaged with said first spiral wrap to
form a series of compression pockets, and a second aperture extending
through said second end plate, said first aperture being in communication
with a first of said compression pockets to provide communication between
said first compression pocket and said first chamber and said second
aperture being in communication with a second of said compression
pockets; and a capacity modulation assembly including: a first piston
located within said first chamber and displaceable between first and
second positions, said first piston isolating said first passage from
communication with said second passage when in the first and second
positions, said first piston preventing communication between said first
aperture and said first passage when in the first position, and said
first piston providing communication between said first aperture and said
first passage when in the second position; a biasing member biasing said
first piston in one of said first and second positions; a first actuation
mechanism in communication with said second passage and selectively
providing a fluid to said second passage to overcome said biasing member
and displace said first piston in another of said first and second
positions. a structure supporting said second scroll member for orbital
displacement relative to said first scroll member and including a second
chamber generally aligned with said second aperture and third and fourth
passages in communication therewith; a second piston located within said
second chamber and axially displaceable between first and second
positions, said second piston isolating said third passage from
communication from said fourth passage when in the first and second
positions, said second piston preventing communication between said
second aperture and said third passage when in the first position, and
said second piston providing communication between said second aperture
and said third passage when in the second position; and a second
actuation mechanism in communication with a pressure source and said
fourth passage and selectively providing pressure to said fourth passage
to displace said second piston between said first and second positions.

18. A compressor comprising: a first scroll member having a first end
plate, a first spiral wrap extending from a first side of said first end
plate, a first chamber located on a second side of said first end plate
having first and second passages in communication therewith, and a first
aperture extending through said first end plate and in communication with
said first chamber, a second scroll member having a second end plate, a
second spiral wrap extending from said second end plate and meshingly
engaged with said first spiral wrap to form a series of compression
pockets, and a second aperture extending through said second end plate; a
first piston located within said first chamber and displaceable between
first and second positions, said first piston preventing communication
between said first aperture and said first passage when in the first
position, and said first piston providing communication between said
first aperture and said first passage when in the second position; a
structure supporting said second scroll member for orbital displacement
relative to said first scroll member and including a recess generally
aligned with said second aperture and third and fourth passages in
communication with said recess; and a second piston located within said
recess and axially displaceable between first and second positions, said
second piston preventing communication between said second aperture and
said third passage when in said first position, and said second piston
providing communication between said second aperture and said third
passage when in said second position, said first piston being in said
first position and said second piston being in said first position to
provide a first level of capacity modulation, one of said first and
second pistons being in said first position and the other of said first
and second pistons being in said second position to provide a second
level of capacity modulation, said first piston being in said second
position and said second piston being in said second position to provide
a third level of capacity modulation, said first level of capacity
modulation being full capacity operation, said second level of capacity
modulation being operation at a capacity less than said first level of
capacity modulation, and said third level of capacity modulation being
operation at a capacity less than said second level of capacity
modulation.

19. The compressor of claim 18, wherein said first piston abuts said
first end plate and said second piston abuts said second end plate when
operating in said first level of capacity modulation.

20. The compressor of claim 18, wherein said first piston abuts said
first end plate and said second piston is spaced from said second end
plate when operating in said second level of capacity modulation.

21. The compressor of claim 18, wherein said first piston is spaced from
said first end plate and said second piston abuts said second end plate
when operating in said second level of capacity modulation.

22. The compressor of claim 18, wherein said first piston abuts an
annular ring and said second piston abuts said fourth passage when
operating in said third level of capacity modulation.

Description:

FIELD

[0001] The present disclosure relates to compressors, and more
specifically to compressors having capacity modulation systems.

BACKGROUND

[0002] This section provides background information related to the present
disclosure which is not necessarily prior art.

[0003] Scroll compressors include a variety of capacity modulation
mechanisms to vary operating capacity of the compressor. The capacity
modulation mechanisms may include fluid passages extending though a
scroll member to selectively provide fluid communication between
compression pockets and another pressure region of the compressor.

SUMMARY

[0004] This section provides a general summary of the disclosure, and is
not a comprehensive disclosure of its full scope or all of its features.

[0005] In one form, a compressor is provided and may include a housing
having a discharge pressure region and a suction pressure region. A first
scroll member may be supported within the housing and may have a first
end plate, a first spiral wrap extending from a first side of the first
end plate, a first chamber located on a second side of the first end
plate having first and second passages in communication therewith, and a
first aperture extending through the first end plate and in communication
with the first chamber. A second scroll member may be supported within
the housing and may include a second end plate having a second spiral
wrap extending therefrom that is meshingly engaged with the first spiral
wrap to form a series of compression pockets and a second aperture
extending therethrough. The first aperture may be in communication with a
first of the compression pockets to provide communication between the
first compression pocket and the first chamber. The second aperture may
be in communication with a second of the compression pockets.

[0006] A capacity modulation assembly may include a first piston located
within the first chamber and displaceable between first and second
positions. The first piston may prevent communication between the first
aperture and the first passage when in the first position, and the first
piston may provide communication between the first aperture and the first
passage when in the second position. A structure may support the second
scroll member for orbital displacement relative to the first scroll
member and may include a recess generally aligned with the second
aperture and third and fourth passages in communication with the recess.
A second piston may be located within the recess and may be axially
displaceable between first and second positions. The second piston may
prevent communication between the second aperture and the third passage
when in the first position, and the second piston may provide
communication between the second aperture and the third passage when in
the second position.

[0007] In some embodiments, a floating seal assembly may be engaged with
the housing and the first scroll member to isolate the discharge pressure
region from the suction pressure region.

[0008] In some embodiments, the first piston is located axially between
the floating seal assembly and the first end plate.

[0009] In some embodiments, the first piston is axially displaceable
relative to the floating seal assembly.

[0010] In some embodiments, a biasing member biases the first piston
toward the second position.

[0011] In some embodiments, the first passage extends radially through the
first scroll member and into the first chamber, the second passage
extends radially through the first scroll member and into the first
chamber, the third passage extends radially through the second scroll
member and into the recess, and the fourth passage extends radially
through the second scroll member and into the recess.

[0012] In some embodiments, the first piston abuts the first end plate
when in the first position.

[0013] In some embodiments, a solenoid may include a communication passage
selectively providing communication between the second passage and an
annular recess. When the solenoid provides communication between the
second passage and the annular recess, the first piston may be in the
first position, and when the solenoid prevents communication between the
second passage and the annular recess, the first piston may be in the
second position.

[0014] In some embodiments, a valve assembly may be in communication with
the second passage and may selectively provide a pressurized fluid to the
second passage to bias the first piston toward the first end plate.

[0015] In some embodiments, the first chamber may be an annular chamber,
the recess may be an annular recess, the first piston may be an annular
piston, and the second piston may be an annular piston.

[0016] In some embodiments, the first scroll member may be a non-orbiting
scroll, and the second scroll member may be an orbiting scroll.

[0017] In some embodiments, the first passage may be in communication with
the suction pressure region.

[0018] In some embodiments, the third passage may be in communication with
the suction pressure region.

[0019] In some embodiments, a valve mechanism may be in communication with
the fourth passage and may selectively provide a pressurized fluid to the
fourth passage to bias the second piston toward the second end plate.

[0020] In some embodiments, the second piston may abut the second end
plate when in the first position.

[0021] In some embodiments, a valve operable in a pulse width modulation
capacity mode may operate the compressor at an intermediate capacity
between full capacity and zero capacity.

[0022] In another form, a compressor is provided and may include a shell
assembly having a suction pressure region and a discharge pressure
region. A first scroll member may be supported within the shell assembly
and may have a first end plate, a first spiral wrap extending from a
first side of the first end plate, a first chamber located on a second
side of the first end plate having first and second passages in
communication therewith, and a first aperture extending through the first
end plate and in communication with the first chamber. A second scroll
member may be supported within the shell assembly and may have a second
end plate, a second spiral wrap extending from the second end plate and
meshingly engaged with the first spiral wrap to form a series of
compression pockets, and a second aperture extending through the second
end plate. The first aperture may be in communication with a first of the
compression pockets to provide communication between the first
compression pocket and the first chamber. The second aperture may be in
communication with a second of the compression pockets.

[0023] A capacity modulation assembly may include a first piston located
within the first chamber and displaceable between first and second
positions. The first piston may isolate the first passage from
communication with the second passage when in the first and second
positions. The first piston may prevent communication between the first
aperture and the first passage when in the first position. The first
piston may provide communication between the first aperture and the first
passage when in the second position. A biasing member may bias the first
piston in one of the first and second positions. A first actuation
mechanism may be in communication with the second passage and may
selectively provide a fluid to the second passage to overcome the biasing
member and displace the first piston in another of the first and second
positions.

[0024] A structure may support the second scroll member for orbital
displacement relative to the first scroll member. The structure may
include a second chamber generally aligned with the second aperture and
third and fourth passages in communication therewith. A second piston may
be located within the second chamber and axially displaceable between
first and second positions. The second piston may isolate the third
passage from communication from the fourth passage when in the first and
second positions. The second piston may prevent communication between the
second aperture and the third passage when in the first position. The
second piston may provide communication between the second aperture and
the third passage when in the second position. A second actuation
mechanism may be in communication with a pressure source and the fourth
passage and may selectively provide pressure to the fourth passage to
displace the second piston between the first and second positions.

[0025] In another form, a compressor may include a first scroll member
having a first end plate, a first spiral wrap extending from a first side
of the first end plate, a first chamber located on a second side of the
first end plate having first and second passages in communication
therewith, and a first aperture extending through the first end plate and
in communication with the first chamber. A second scroll member may have
a second end plate, a second spiral wrap extending from the second end
plate and meshingly engaged with the first spiral wrap to form a series
of compression pockets, and a second aperture extending through the
second end plate. The first piston may be located within the first
chamber and may be displaceable between first and second positions. The
first piston may prevent communication between the first aperture and the
first passage when in the first position, and the first piston may
provide communication between the first aperture and the first passage
when in the second position.

[0026] A structure may support the second scroll member for orbital
displacement relative to the first scroll member and may include a recess
generally aligned with the second aperture and third and fourth passages
in communication with the recess. A second piston may be located within
the recess and may be axially displaceable between first and second
positions. The second piston may prevent communication between the second
aperture and the third passage when in the first position, and the second
piston may provide communication between the second aperture and the
third passage when in the second position.

[0027] The first piston may be in the first position and the second piston
may be in the first position to provide a first level of capacity
modulation. The first piston may be in the first position and the second
piston may be in the second position to provide a second level of
capacity modulation. The first piston may be in the second position and
the second piston may be in the second position to provide a third level
of capacity modulation. The first level of capacity modulation may be
full capacity operation, the second level of capacity modulation may be
operation at a capacity less than the first level of capacity modulation,
and the third level of capacity modulation may be operation at a capacity
less than the second level of capacity modulation.

[0028] In some embodiments, the first piston abuts the first end plate and
the second piston abuts the second end plate when operating in the first
level of capacity modulation.

[0029] In some embodiments, the first piston abuts the first end plate and
the second piston abuts the fourth passage when operating in the second
level of capacity modulation.

[0030] In some embodiments, the first piston abuts an annular ring and the
second piston abuts the fourth passage when operating in the third level
of capacity modulation.

[0031] Further areas of applicability will become apparent from the
description provided herein. The description and specific examples in
this summary are intended for purposes of illustration only and are not
intended to limit the scope of the present disclosure.

DRAWINGS

[0032] The drawings described herein are for illustrative purposes only of
selected embodiments and not all possible implementations, and are not
intended to limit the scope of the present disclosure.

[0033] FIG. 1 is a cross-sectional view of a compressor according to the
present disclosure;

[0034] FIG. 2 is a cross-sectional view of an orbiting scroll, a
non-orbiting scroll, a seal assembly, and a modulation system of the
compressor of FIG. 1 showing the compressor in a full-capacity state;

[0035] FIG. 3 is a cross-sectional view of an orbiting scroll, a
non-orbiting scroll, a seal assembly, and a modulation system of the
compressor of FIG. 1 showing the compressor in a reduced-capacity state;

[0036] FIG. 4 is a cross-sectional view of an orbiting scroll, a
non-orbiting scroll, a seal assembly, and a modulation system of the
compressor of FIG. 1 showing the compressor in a reduced-capacity state;

[0037] FIG. 5 is a plan view of an orbiting scroll and a non-orbiting
scroll of the compressor of FIG. 1;

[0038] FIG. 6 is a plan view of an orbiting scroll and a non-orbiting
scroll of the compressor of FIG. 1;

[0039] FIG. 7 is a plan view of an orbiting scroll and a non-orbiting
scroll of the compressor of FIG. 1;

[0040] FIG. 8 is a cross-sectional view of a non-orbiting scroll, seal
assembly, and modulation system according to the present disclosure;

[0041] FIG. 9 is a cross-sectional view of the non-orbiting scroll, seal
assembly, and modulation system of FIG. 8;

[0042] FIG. 10 is a cross-sectional view of a non-orbiting scroll, seal
assembly, and modulation system according to the present disclosure;

[0043] FIG. 11 is a cross-sectional view of the non-orbiting scroll, seal
assembly, and modulation system of FIG. 10;

[0044] FIG. 12 is a flow diagram detailing operation of the compressors of
FIGS. 1, 8, and 10.

[0045] Corresponding reference numerals indicate corresponding parts
throughout the several views of the drawings.

DETAILED DESCRIPTION

[0046] The following description is merely exemplary in nature and is not
intended to limit the present disclosure, application, or uses. It should
be understood that throughout the drawings, corresponding reference
numerals indicate like or corresponding parts and features.

[0047] Example embodiments are provided so that this disclosure will be
thorough, and will fully convey the scope to those who are skilled in the
art. Numerous specific details are set forth such as examples of specific
components, devices, and methods, to provide a thorough understanding of
embodiments of the present disclosure. It will be apparent to those
skilled in the art that specific details need not be employed, that
example embodiments may be embodied in many different forms and that
neither should be construed to limit the scope of the disclosure. In some
example embodiments, well-known processes, well-known device structures,
and well-known technologies are not described in detail.

[0048] The terminology used herein is for the purpose of describing
particular example embodiments only and is not intended to be limiting.
As used herein, the singular forms "a," "an," and "the" may be intended
to include the plural forms as well, unless the context clearly indicates
otherwise. The terms "comprises," "comprising," "including," and
"having," are inclusive and therefore specify the presence of stated
features, integers, steps, operations, elements, and/or components, but
do not preclude the presence or addition of one or more other features,
integers, steps, operations, elements, components, and/or groups thereof.
The method steps, processes, and operations described herein are not to
be construed as necessarily requiring their performance in the particular
order discussed or illustrated, unless specifically identified as an
order of performance. It is also to be understood that additional or
alternative steps may be employed.

[0049] When an element or layer is referred to as being "on," "engaged
to," "connected to," or "coupled to" another element or layer, it may be
directly on, engaged, connected or coupled to the other element or layer,
or intervening elements or layers may be present. In contrast, when an
element is referred to as being "directly on," "directly engaged to,"
"directly connected to," or "directly coupled to" another element or
layer, there may be no intervening elements or layers present. Other
words used to describe the relationship between elements should be
interpreted in a like fashion (e.g., "between" versus "directly between,"
"adjacent" versus "directly adjacent," etc.). As used herein, the term
"and/or" includes any and all combinations of one or more of the
associated listed items.

[0050] Although the terms first, second, third, etc. may be used herein to
describe various elements, components, regions, layers and/or sections,
these elements, components, regions, layers and/or sections should not be
limited by these terms. These terms may be only used to distinguish one
element, component, region, layer or section from another region, layer
or section. Terms such as "first," "second," and other numerical terms
when used herein do not imply a sequence or order unless clearly
indicated by the context. Thus, a first element, component, region, layer
or section discussed below could be termed a second element, component,
region, layer or section without departing from the teachings of the
example embodiments.

[0051] Spatially relative terms, such as "inner," "outer," "beneath,"
"below," "lower," "above," "upper," and the like, may be used herein for
ease of description to describe one element or feature's relationship to
another element(s) or feature(s) as illustrated in the figures. Spatially
relative terms may be intended to encompass different orientations of the
device in use or operation in addition to the orientation depicted in the
figures. For example, if the device in the figures is turned over,
elements described as "below" or "beneath" other elements or features
would then be oriented "above" the other elements or features. Thus, the
example term "below" can encompass both an orientation of above and
below. The device may be otherwise oriented (rotated 90 degrees or at
other orientations) and the spatially relative descriptors used herein
interpreted accordingly.

[0052] The present teachings are suitable for incorporation in many
different types of scroll and rotary compressors, including hermetic
machines, open-drive machines and non-hermetic machines. For exemplary
purposes, a compressor 10 is shown as a hermetic scroll
refrigerant-compressor of the low-side type (i.e., where the motor and
compressor are cooled by suction gas in the hermetic shell), as
illustrated in the vertical section shown in FIG. 1.

[0053] With reference to FIG. 1, compressor 10 is provided and may include
a hermetic shell assembly 12, a main bearing housing assembly 14, a motor
assembly 16, a compression mechanism 18, a seal assembly 20, a
refrigerant discharge fitting 22, a discharge valve assembly 24, a
suction gas inlet fitting 26, a first modulation assembly 28, and a
second modulation assembly 30. Shell assembly 12 may house main bearing
housing assembly 14, motor assembly 16, and compression mechanism 18.

[0054] Shell assembly 12 may generally form a compressor housing and may
include a cylindrical shell 32, an end cap 34 at the upper end thereof, a
transversely extending partition 36, and a base 38 at a lower end
thereof. End cap 34 and partition 36 may generally define a discharge
chamber 40. Discharge chamber 40 may generally form a discharge muffler
for compressor 10. Refrigerant discharge fitting 22 may be attached to
shell assembly 12 at opening 42 in end cap 34. Discharge valve assembly
24 may be located within discharge fitting 22 and may generally prevent a
reverse-flow condition. Suction gas inlet fitting 26 may be attached to
shell assembly 12 at opening 44. Partition 36 may include a discharge
passage 46 therethrough, providing communication between compression
mechanism 18 and discharge chamber 40.

[0055] Main bearing housing assembly 14 may be affixed to shell 32 at a
plurality of points in any desirable manner, such as staking. Main
bearing housing assembly 14 may include a main bearing housing 48, a
first bearing 50 disposed therein, bushings 52, and fasteners 54. Main
bearing housing 48 may include a central body portion 56 having a series
of arms 58 extending radially outwardly therefrom. Central body portion
56 may include first and second portions 60, 62 having an opening 64
extending therethrough. Second portion 62 may house first bearing 50
therein. First portion 60 may define an annular flat thrust bearing
surface 66 on an axial end surface thereof. Arm 58 may include apertures
68 extending therethrough and receiving fasteners 54.

[0056] Main bearing housing 48 may further include an annular passage 70
that forms an annular recess extending into thrust bearing surface 72.
First radial passages 74 may extend radially through first portion 60 and
into annular passage 70, providing communication between annular passage
70 and a suction pressure region. A second radial passage 76 may extend
radially through first portion 60 and into annular passage 70 and may be
in communication with capacity adjustment assembly 78, as discussed
below.

[0057] Motor assembly 16 may generally include a motor stator 80, a rotor
82, and a drive shaft 84. Windings 86 may pass through stator 80. Motor
stator 80 may be press fit into shell 32. Drive shaft 84 may be rotatably
driven by rotor 82. Rotor 82 may be press fit on drive shaft 84. Drive
shaft 84 may include an eccentric crank pin 88 having a flat 90 thereon.

[0058] Compression mechanism 18 may generally include an orbiting scroll
100 and a non-orbiting scroll 102. Orbiting scroll 100 may include an end
plate 104 having a spiral vane or wrap 106 on the upper surface thereof
and an annular flat thrust surface 108 on the lower surface. Thrust
surface 108 may interface with annular flat thrust bearing surface 66 on
main bearing housing 48. A cylindrical hub 110 may project downwardly
from thrust surface 108 and may have a drive bushing 112 rotatively
disposed therein. Drive bushing 112 may include an inner bore in which
crank pin 88 is drivingly disposed. Crank pin flat 90 may drivingly
engage a flat surface in a portion of the inner bore of drive bushing 112
to provide a radially compliant driving arrangement. An Oldham coupling
114 may be engaged with the orbiting scroll 100 to prevent relative
rotation between the orbiting and non-orbiting scrolls 100, 102.

[0059] With additional reference to FIGS. 2-7, non-orbiting scroll 102 may
include an end plate 116 having a spiral wrap 118 on a lower surface
thereof, a series of radially outwardly extending flanged portions 120
(FIG. 5), and may receive an annular ring 122. Spiral wrap 118 may form a
meshing engagement with wrap 106 of orbiting scroll 100, thereby creating
an inlet pocket 124, intermediate pockets 126, 128, 130, 132, and an
outlet pocket 134. Non-orbiting scroll 102 may be axially displaceable
relative to main bearing housing assembly 14, shell assembly 12, and
orbiting scroll 100. Non-orbiting scroll 102 may include a discharge
passage 136 in communication with outlet pocket 134 and an upwardly open
recess 138 that may be in fluid communication with discharge chamber 40
via discharge passage 46 in partition 36.

[0061] Non-orbiting scroll 102 may include an annular recess 142 in the
upper surface thereof defined by parallel, coaxial inner and outer side
walls 144, 146. Annular ring 122 may be disposed within annular recess
142 and may separate annular recess 142 into first and second annular
recesses 148, 150 that are isolated from one another. First annular
recess 148 may provide for axial biasing of non-orbiting scroll 102
relative to orbiting scroll 100, as discussed below. More specifically, a
passage 152 may extend through end plate 116 of non-orbiting scroll 102,
placing first annular recess 148 in fluid communication with one of
intermediate pockets 126, 128, 130, 132. While passage 152 is shown
extending into intermediate pocket 126, passage 152 may alternatively be
placed in communication with any of the other intermediate pockets 126,
128, 130, 132.

[0062] Additional passages 154, 156 may extend through end plate 116,
placing second annular recess 150 in fluid communication with two of
intermediate fluid pockets 126, 128, 130, 132. Second annular recess 150
may be in fluid communication with different intermediate fluid pockets
126, 128, 130, 132 than first annular recess 148. More specifically,
second annular recess 150 may be in fluid communication with intermediate
fluid pockets 126, 128, 130, 132 located radially outwardly relative to
the intermediate fluid pocket 126, 128, 130, 132 in fluid communication
with first annular recess 148. Therefore, first annular recess 148 may
operate at a pressure greater than an operating pressure of second
annular recess 150. First and second radial passages 158, 160 may extend
into second annular recess 150 and may cooperate with second modulation
assembly 30, as discussed below.

[0063] Seal assembly 20 may include a floating seal located within first
annular recess 148. Seal assembly 20 may be axially displaceable relative
to shell assembly 12 and non-orbiting scroll 102 to provide for axial
displacement of non-orbiting scroll 102 while maintaining a sealed
engagement with partition 36 to isolate discharge and suction pressure
regions of compressor 10 from one another. More specifically, pressure
within first annular recess 148 may urge seal assembly 20 into engagement
with partition 36 during normal compressor operation.

[0064] Second modulation assembly 30 may include a piston assembly 162, a
solenoid 164, and a biasing member 168. Piston assembly 162 may include
an annular piston 170 and first and second annular seals 172, 174.
Annular piston 170 may be located in second annular recess 150 and first
and second annular seals 172, 174 may be engaged with inner and outer
side walls 144, 146 to separate second annular recess 150 into first and
second portions 176, 178 that are isolated from one another. First
portion 176 may be in communication with first radial passage 158 and
second portion 178 may be in communication with second radial passage
160. Solenoid 164 may include a connecting passage 180 in fluid
communication with a third radial passage 182 and with first radial
passage 158. Accordingly, connecting passage 180 is in fluid
communication with first annular recess 148 and first portion 176 via
third radial passage 182 and first radial passage 158, respectively.
Biasing member 168 may include a spring that is located in second portion
178 and is engaged with annular piston 170.

[0065] Annular piston 170 is displaceable between first and second
positions. In the first position (FIGS. 2, 3, 5 and 6), annular piston
170 seals passages 154, 156 from communication with second portion 178 of
second annular recess 150. Further, solenoid 164 is in a first position
and provides communication between first portion 176 and first annular
recess 148. In so doing, solenoid 164 provides first portion 176 with
fluid at an intermediate pressure that is higher than suction pressure
and lower than discharge pressure. The intermediate pressure fluid is
communicated to first portion 176 via recess 148 and passages 182, 158,
whereby recess 148 receives the intermediate pressure fluid from pocket
126 via passage 152. The force of the intermediate pressure fluid acts on
annular piston 170, thereby causing piston 170 to engage and close
passages 154, 156.

[0066] In the second position (FIGS. 4 and 7), annular piston 170 is
displaced from passages 154, 156, providing communication between
passages 154, 156 and second portion 178 of second annular recess 150.
Solenoid 164 is likewise displaced to a second position to prevent
communication between first portion 176 and first annular recess 148. In
so doing, first portion 176 is placed under suction pressure, which
allows biasing member 168 to move annular piston 170 away from and open
passages 154, 156. Therefore, when annular piston 170 and solenoid 164
are in the second position, passages 154, 156 are placed in communication
with a suction pressure region of compressor 10 via second radial passage
160 to provide a first reduced capacity operating mode for compressor 10.

[0067] Orbiting scroll 100 may include first and second passages 184, 186
extending through end plate 104 and providing communication between two
of intermediate fluid pockets 126, 128, 130, 132 and annular passage 70.
Intermediate fluid pockets 126, 128, 130, 132 in communication annular
passage 70 may be different than intermediate fluid pockets 126, 128,
130, 132 in communication with annular recess 148. More specifically,
intermediate fluid pockets 126, 128, 130, 132 in communication with
annular recess 148 may be located radially inwardly relative to and
operate at a pressure greater than intermediate fluid pockets 126, 128,
130, 132 in communication with annular passage 70.

[0068] First modulation assembly 28 may include a piston assembly 188, and
a valve assembly 190. Piston assembly 188 may include an annular piston
192 located in annular passage 70. Annular piston 192 may be displaceable
between first and second positions. In the first position (FIGS. 2 and
5), annular piston 192 isolates first and second passages 184, 186 from
first radial passage 74. In the second position (FIGS. 3, 4, 6 and 7),
annular piston 192 is displaced to provide communication between first
and second passages 184, 186 and first radial passage 74. In the second
position, first and second passages 184, 186 are in communication with a
suction pressure region of compressor 10 via first radial passage 74
providing compressor 10 with a reduced capacity operating mode. In both
the first and second positions, annular piston 192 isolates first and
second radial passages 74, 76 from one another and additionally isolates
first and second passages 184, 186 from second radial passage 76.

[0069] Valve assembly 190 may include a valve member 194 in communication
with a pressure source 196 and with second radial passage 76. A biasing
member (not illustrated) may be included in annular passage 70 and may be
disposed between annular piston 192 and end plate 104. The biasing member
may include a spring and may be engaged with annular piston 192 to bias
piston 192 in a direction away from end plate 104. Valve assembly 190 may
displace annular piston 192 between the first and second positions by
selectively supplying radial passage 76 with pressurized fluid.

[0070] Valve member 194 may provide communication between pressure source
196 and second radial passage 76 to bias annular piston 192 to the first
position. For example, the pressure source 196 may provide radial passage
76 with discharge pressure fluid from discharge chamber 40. Fluid at
discharge pressure is at a pressure that is greater than an operating
pressure of intermediate pockets 126, 128, 130, 132. Accordingly, the
discharge pressure fluid overcomes the biasing force exerted on annular
piston 192 by the biasing member disposed between annular piston 192 and
end plate 104 and, as a result, maintains annular piston 192 in
engagement with end plate 104. Further, the discharge pressure fluid in
radial passage 76 is at a pressure that is greater than the intermediate
pressure fluid disposed within passages 184, 186 acting on annular piston
192 and therefore maintains piston 192 in contact with end plate 104.
Such engagement closes passages 184, 186 and prevents fluid communication
between passages 184, 186 and suction pressure via radial passage 74.

[0071] Valve member 194 prevents communication between pressure source 196
and second radial passage 76 and may vent second radial passage 76 to a
suction pressure region to allow annular piston 192 to be displaced to
the second position. The biasing member disposed between annular piston
192 and end plate 104 may generally bias annular piston 192 to the second
position when second radial passage 76 is vented to suction pressure.

[0072] With reference generally to FIGS. 1-7, a three-step modulation
system 200 is provided and may include a full-capacity mode or first
level of capacity modulation, a modulation step-one mode or second level
of capacity modulation, and a modulation step-two mode or third level of
capacity modulation. Under the different modes of operation, compressor
10 selectively activates first modulation assembly 28 and second
modulation assembly 30 to optimize a capacity of compressor 10. When
annular pistons 192, 170 of the first modulation assembly 28 and second
modulation assembly 30 are in the first position, compressor 10 operates
at full capacity (FIGS. 2 and 5). When operating at full capacity, the
entire compression cycle is utilized and compressor 10 achieves maximum
performance (i.e., one hundred percent capacity).

[0073] When valve member 194 of first modulation assembly 28 displaces
annular piston 192 to the second position, second radial passage 76 is
vented to suction pressure. When compressor 10 operates with annular
piston 192 of first modulation assembly 28 in the second position, and
annular piston 170 of second modulation assembly 30 in the first
position, compressor 10 operates in modulation step-one mode (FIGS. 3 and
6). When operating in modulation step-one mode, compressor 10 operates at
a reduced capacity from full capacity (roughly seventy percent total
capacity). Namely, because annular piston 192 vents initial compression
to suction pressure, the entire compression cycle is not utilized and as
a result, the maximum possible output of compressor 10 is not achieved.

[0074] When annular piston 170 is displaced to the second position,
passages 154, 156 are vented to a suction pressure region of compressor
10 through second radial passage 160. When compressor 10 operates with
annular piston 170 of second modulation assembly 30 in the second
position and annular piston 192 of first modulation assembly 28 in the
second position, compressor 10 operates in modulation step-two mode
(FIGS. 4 and 7). When operating in modulation step-two mode, compressor
10 operates at a reduced capacity when compared to modulation step-one
mode (roughly fifty percent total capacity). Namely, because annular
pistons 170, 192 vent initial compression to the suction pressure regions
of compressor 10, the entire compression cycle is not utilized and, as a
result, the maximum possible output of compressor 10 is not achieved. In
fact, when compressor 10 is operating in step-two mode, an output of
compressor 10 is less than when compressor 10 is operating in step-one
mode.

[0075] Compressor 10 might operate at full capacity under normal
circumstances and reduced capacity in the modulation step-one and
modulation step-two modes based on a demand of a system (i.e., a
refrigeration system) in which compressor 10 is installed. However,
compressor 10 might also operate in modulation step-two in a normal
operating mode and change to operate in modulation step-one or at full
capacity if demand is increased. Further, compressor 10 might operate in
modulation step-one and have the variability to increase capacity (with
full capacity operation) or decrease capacity (with modulation step-two
operation) if required.

[0076] With reference to FIGS. 8 and 9, an alternate non-orbiting scroll
302 and modulation assembly 330 are shown. Non-orbiting scroll 302 may be
generally similar to non-orbiting scroll 102. Therefore, the description
of non-orbiting scroll 102 applies equally to non-orbiting scroll 302
with the exceptions indicated below. Further, non-orbiting scroll 302 and
modulation assembly 330 may be incorporated into a compressor such as
compressor 10 in place of non-orbiting scroll 102 and second modulation
assembly 30 and may function in place of second modulation assembly 30 in
the three-step modulation system.

[0077] Modulation assembly 330 may include a piston assembly 362, a valve
assembly 380, and a biasing member 368. Piston assembly 362 may include
an annular piston 370 and first and second annular seals 372, 374.
Annular piston 370 may be located in second annular recess 350 and first
and second annular seals 372, 374 may be engaged with inner and outer
side walls 344, 346 to separate second annular recess 350 into first and
second portions 376, 378 that are isolated from one another. First
portion 376 may be in communication with first radial passage 358 and
second portion 378 may be in communication with second radial passage
360. Valve assembly 380 may include a valve member 382 in communication
with a pressure source 384, with first radial passage 358, and with first
portion 376. Biasing member 368 may include a spring and may be located
in second portion 378 and may be engaged with annular piston 370.

[0078] Annular piston 370 may be displaceable between first and second
positions. In the first position (FIG. 8), annular piston 370 may seal
passages 354, 356 from communication with second portion 378 of second
annular recess 350. In the second position (FIG. 9), annular piston 370
may be displaced from passages 354, 356, providing communication between
passages 354, 356 and second portion 378 of second annular recess 350.
Therefore, when annular piston 370 is in the second position, passages
354, 356 may be in communication with a suction pressure region of
compressor 10 via second radial passage 360 providing a reduced-capacity
operating mode for compressor 10.

[0079] Pressure source 384 may include a pressure that is greater than an
operating pressure of intermediate pockets 126, 128, 130, 132. For
example, pressure source 384 may be discharge-pressure fluid received
from discharge chamber 40 (FIG. 1) and, therefore, may be at discharge
pressure. Valve member 382 may provide communication between pressure
source 384 and first portion 376 of second annular recess 350 to displace
annular piston 370 to the first position. Valve member 382 may likewise
prevent communication between pressure source 384 and first portion 376
of second annular recess 350 to displace annular piston 370 to the second
position. Valve member 382 may additionally vent first portion 376 to the
suction pressure region of compressor 10 to displace annular piston 370
to the second position. Biasing member 368 may generally bias annular
piston 370 toward the second position. In addition, intermediate-pressure
fluid disposed within compression pockets of compressor 10 may act on
annular piston 370 to urge annular piston 370 away from passages 354,
356. Such intermediate-pressure fluid is permitted to move annular piston
370 away from passages 354, 356 when discharge-pressure fluid is not
present in first portion 376.

[0080] With reference to FIGS. 10 and 11, an alternate non-orbiting scroll
402 and modulation assembly 430 are shown. Non-orbiting scroll 402 may be
generally similar to non-orbiting scroll 102. Therefore, the description
of non-orbiting scroll 102 applies equally to non-orbiting scroll 402
with the exceptions indicated below. Further, non-orbiting scroll 402 and
modulation assembly 430 may be incorporated into a compressor such as
compressor 10 in place of non-orbiting scroll 102 and second modulation
assembly 30 and may function in place of second modulation assembly 30 in
the three-step modulation system.

[0081] Non-orbiting scroll 402 may include a passage 486 extending between
and providing communication between first annular recess 448 and first
portion 476 of second annular recess 450. Modulation assembly 430 may
include a valve assembly 480 having a valve member 482 located in radial
passage 458. Valve member 482 may be displaceable between first and
second positions to displace annular piston 470 between first and second
positions by selectively supplying first portion 476 with intermediate
pressure fluid from annular recess 448. Namely, when valve member 482
supplies first portion 476 with intermediate pressure fluid, annular
piston 470 is biased toward passages 454, 456. Conversely, when valve
member 482 prevents intermediate pressure fluid from reaching first
portion 476 by blocking passage 486 (FIG. 11), annular piston 470 moves
away from and opens passages 454, 456 under the force of biasing member
468 and the intermediate pressure fluid disposed within passages 454,
456. The first and second positions of annular piston 470 and
corresponding capacity reduction may be generally similar to that
discussed above for second modulation assembly 30. Therefore, for
simplicity, the description will not be repeated with the understanding
that the above description applies equally to the modulation assembly
430.

[0082] Valve member 482 may provide communication between the first and
second annular recesses 448, 450 when valve member 482 is in the first
position (FIG. 10). Because first annular recess 448 operates at a higher
pressure (i.e., intermediate pressure) than second annular recess 450,
annular piston 470 may be displaced (or held) in the first position when
valve member 482 permits intermediate pressure fluid to reach first
portion 476 via passage 486. Valve member 482 may be displaced to the
second position and vent first portion 476 of second annular recess 450
to suction pressure in order to displace annular piston 470 to the second
position (FIG. 11). In the second position, valve member 482 may seal
passage 486 to isolate first and second annular recesses 448, 450 from
one another. When first and second annular recesses 448, 450 are isolated
from one another, biasing member 468 may urge annular piston 470 to the
second position where passages 454, 456 are in communication with a
suction pressure region.

[0083] Referring to FIGS. 1-11, providing communication between the first
annular recess 148, 348, 448 and the suction pressure region may remove
the axial biasing force received from passage 152 that normally urges
non-orbiting scroll 102, 302, 402 toward orbiting scroll 104. In so
doing, a reduced compressor operating capacity is provided by causing
axial separation of the non-orbiting scroll 102, 302, 402 from the
orbiting scroll 100. The capacity is reduced to zero when the axial
biasing force is removed and the axial clearance exists between the
orbiting scroll 100 and the particular non-orbiting scrolls 102, 302,
402.

[0084] Now referring to FIG. 12, a method 600 of controlling compressor 10
is illustrated. Method 600 operates compressor 10 with first annular
piston 170 and second annular piston 192 in the first position at 602.
While the method 600 will be described in conjunction with compressor 10
incorporating annular piston 170, compressor 10 could alternatively
incorporate either of annular pistons 370, 470 in place of annular piston
170. Namely, a controller 500 (FIG. 1) associated with first modulation
assembly 28 and second modulation assembly 30 controls solenoid 164 and
valve member 194 to position first annular piston 170 and second annular
piston 192 in the first position at 602. At 604, the current compressor
capacity is determined. The current capacity may be determined from
sensor readings or inputs from a user. At 606, the desired compressor
capacity is determined. The desired capacity may be determined from a
plurality of parameters entered by a user and/or based on sensor readings
associated with compressor 10 and/or with a system in which compressor 10
is installed.

[0085] At 608, method 600 determines whether the desired capacity is less
than a first desired threshold. The first desired threshold may be the
threshold between the first level of capacity modulation and the second
level of capacity modulation. The first desired threshold may be variable
based on the application of compressor 10 and may be input by a user. If
false, compressor 10 continues operation at the first level of capacity
modulation, with first and second annular pistons 170, 192 in the first
position, at 610.

[0086] If true at 608, method 600 determines whether the desired capacity
is less than the second desired threshold at 612. The second desired
threshold may be the threshold between the second level of capacity
modulation and the third level of capacity modulation. The second desired
threshold may be variable based on the application of the compressor and
may be input by a user. If true, compressor 10 operates at the third
level of capacity modulation, with first and second annular pistons 170,
192 in the second position, at 614. If false at 612, compressor 10
operates at the second level of capacity modulation, with first annular
piston 170 in the first position and second annular piston 192 in the
second position, at 616.

[0087] The flowchart of FIG. 12 provides a method 600 that operates
compressor 10 with first annular piston 170 and second annular piston 192
in the first position at 602 under normal operating conditions. Namely,
method 600 operates compressor 10 at full capacity under normal operating
conditions. Compressor 10 could alternatively be operated such that
compressor 10 operates in modulation step-one under normal operating
conditions to allow a capacity of compressor 10 to be increased to full
capacity if demand is increased and to allow a capacity of compressor 10
to be decreased to modulation step-two if demand is decreased. For
example, compressor 10 could be operated under normal operating
conditions at modulation step-one and could be moved to modulation
step-two if less capacity is required (i.e., demand is decreased).

[0088] Similarly, compressor 10 could be operated at modulation step-two
under normal operating conditions. If compressor 10 is operated at
modulation step-two under normal operating conditions, a capacity of
compressor 10 could be step-wise increased from modulation step-two to
modulation step-one and from modulation step-one to full capacity.
Determining whether to increase capacity of compressor 10 to modulation
step-one or to full capacity may be dependent on how much demand is
increased. For example, if compressor 10 is normally operated at
modulation step-two and demand is only slightly increased, compressor 10
may be moved from modulation step-two to modulation step-one to satisfy
the increased demand. Conversely, if compressor 10 is normally operated
at modulation step-two and demand is significantly increased (i.e., more
than a predetermined amount), compressor 10 may bypass modulation
step-one and be operated at full capacity to satisfy demand.

[0089] In sum, regardless of whether compressor 10 is normally operated at
full capacity (FIG. 12), modulation step-one, or modulation step-two, a
capacity of compressor 10 may be adjusted based on demand to match
compressor output with demand in an effort to increase the efficiency of
compressor 10.

[0090] The foregoing description of the embodiments has been provided for
purposes of illustration and description. It is not intended to be
exhaustive or to limit the disclosure. Individual elements or features of
a particular embodiment are generally not limited to that particular
embodiment, but, where applicable, are interchangeable and can be used in
a selected embodiment, even if not specifically shown or described. The
same may also be varied in many ways. Such variations are not to be
regarded as a departure from the disclosure, and all such modifications
are intended to be included within the scope of the disclosure.